1. ABB Contents. Operating and Maintenance manual 52

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3 1. ABB Contents 1. Contents 3 2. Technical description for ABB Orion 400A type (400 kva), ABB Orion 630A type (630 kva) and ABB Orion 1000M type (1000 kva) concrete compact secondary substations 4 Construction of compact substation 5 Housing material 5 IP protection class of the substation 5 Behaviour of the substation in case of internal faults 5 Temperature rise, ventilation 5 Earthing apparatus 5 Noise emission 6 EMC requirements 6 Doors 6 Roof 6 Corrosion protection 6 Surface finishing 6 Oil collection pit 6 Cable connecting compartment 7 Accessories 7 External dimensions of substation 7 3. Electrical equipment 8 Medium voltage switchgear 9 Medium voltage metering cubicle Type ABB M Transformer room 12 Medium voltage interconnections 13 Low voltage distribution panel 14 General description, Orion 400A type of compact substation 14 Incoming of low voltage panel (Orion 400A) 15 Low voltage outgoings (Orion 400A) 15 General description, Orion 630A type of compact substation 15 Incoming of low voltage panel (Orion 630A) 16 Low voltage outgoings (Orion 630A) 16 General description, Orion 1000M type of compact substation 18 Incoming of low voltage panel (Orion 1000M) 18 Low voltage outgoings (Orion 1000M) 18 Description of optional items 19 Equipment installed into the low voltage distribution panel 19 Overcurrent protection MCBs 19 Low voltage interconnection between transformer and low voltage panel The maximal technical containt of the substation Markings Tests 22 Type tests 16 Routine tests, acceptance tests Standards, guidelines and legislation Attachment Installation Manual for ABB Orion 400A and Orion 630A compact secondary substations 42 Erection 42 Installation Installation Manual for ABB Orion 1000M of compact secondary substations 47 Erection 47 Installation ABB Orion 400A, Orion630A and Orion1000M type concrete compact secondary substations Operating and Maintenance manual 52 3

4 általános leírás Asea Brown Boweri 2. Technical description for ABB Orion 400A type (400 kva), ABB Orion 630A type (630 kva) and ABB Orion 1000M type (1000 kva) concrete compact secondary substations.

5 technical description Construction of compact substation The substation housing consist of an aboveground building portion and a base, and of doors and ventilation surfaces. The equipment is engineered for a technical service lifetime of 40 years. During that period, the equipment will be almost free of maintenance. Housing material The housing is made of concrete which conforms to electric, thermal and mechanic requirements according to standard EN The building is manufactured by casting monolithically, from one piece, and is built without a gap. The compressive strength of concrete conforms to class C35/45. The durability class of concrete according to standard DIN 1045 is XC4; XF1 for the external building element, and XC1 for the internal building element. Option: The compact substation allows installation on a sloped terrain which means that the rear longitudinal side can be filled with earth up to 250 mm beneath roof level. This backfill will have a slope towards according to standard EN On the inner side of door and on the ventilation surface beneath the roof, a wire mesh is installed in order to prevent ingress of insects into the substation. Behaviour of the substation in case of internal faults The compact substation is resistant to arc and complies with criteria according to IEC , approaches IAC-A and IAC-B. Internal arc fault test was performed with a 3-cubicle SF6 insulated switchgear unit (KKT) and a 630 kva rated transformer for Orion 630A type substation, and with a 3-cubicle SF6 insulated switchgear unit (KKT) and a 1000 kva transformer for Orion 1000M type compact substation. The minimum values of testing short-circuit currents and the arc ignition places according to IEC are shown in the following table. Temperature rise, ventilation The substation is designed in such a way that with the use of a normal loss (AC ) transformer with rated around the substation under the roof. The fresh air enters the substation through the ventillation slots of the low voltage door and leaves the substation thru the openings under the roof. In order to ensure that small creatures and insects cannot enter the substation all ventilation openings are covered by mesh and have the IP protection level of IP43D. The heat-run test of the substation was performed according to IEC standard, and an additional heat-run test was also performed according to RWE prescriptions. The thermal class of ORION 400A and ORION 630A is 15K (test value: 15.2K). The thermal class of ORION 1000M is 15K (test value: 13 K). Earthing apparatus The substation electric equipment are earthed via the shortest route possible according to EN standard specifications, and the connecting points of earthing are marked. Each piece of equipment is connected through a NYY 70 mm2 Cu cable to the earthing system of substation. Doors and built-in ventilation units are electrically connected to the door frame through a 1x50 mm2 flexible conductor. The protective earthing of high Medium voltage unit Minimum testing short-circuit current Ignition Arc ignition spot SF 6 insulated unit 20 ka/1s 3 pole Gas compartment 2 pole* Cable compartment * The test short-circuit current has 3-pole infeed so a fault current of 20 ka is produced; for 2-pole ignition the short-circuit current amounts to 17.4 ka. the frontal part, down to the standard excavation depth. IP protection class of the substation The protection class for the whole substation including doors and ventilation units is at least IP43D power corresponding to the rated power of the substation will not jeopardize the continuous operation of the compact substation. The cooling of the substation is solved by natural ventilation. There are ventilation slots in the low voltage door of the substation. The roof is lifted up by 30 mm, so the substation has ventillation openings all voltage units and the normal earthing of low voltage equipment can be separated. In the area of low voltage panel, a shock protection junction - a 300 mm long, 40x10 mm flat steel piece bonding (potential equalization) bar - is installed. Its connectors are durably labelled. Between the PEN busbar and the bonding (potential ABB Catalogue

6 technical description equalization) bar, a detachable flexible Cu link with a cross section of 70 mm2 is installed. The external earthing network of substation can be connected at the right-hand side part of PEN bar, using a dedicated M12 pressed nut. Conductors can be surrounded by means of a commercially available standard earthing tester clamp. The test can also be run within the framework of general maintenance without breaking the joint. For the temporary connection of earthing-shortcircuiting sets, an M12 bolted point for the fixation of earthing is found on the PEN bar. The short circuit withstand capacity and time limit on the earthing network of the substation is 14 ka / 1 s (28 ka/1s peak value). Noise emission Value obtained during noise emission test for Orion 400A and Orion 630A type compact substation: The sound pressure level produced by the substation housing including built-in transformer is by 12.8 db(a) less than the sound pressure level produced by the free-standing transformer. In both cases, the test was carried out at a distance of 0.2 m to the unit and the substation respectively. The sound pressure test was performed according to standard EN Value obtained during noise emission test for Orion 1000M type compact substation: The sound pressure level produced by the substation housing including built-in transformer is by 13.3 db(a) less than the sound pressure level produced by the free-standing transformer. In both cases, the test was carried out at a distance of 0.2 m to the unit and the substation respectively. The sound pressure test was performed according to standard EN EMC requirements As a part of the type test, the electromagnetic field of the substation at full load has been tested. The electromagnetic field strength and the magnetic induction on a relevant boundary surface reckoned from the substation perimeter wall do not exceed 100 µt health limit value specified in the relevant decree. Doors Substation doors comply with arc and pressure withstand criteria. Opening angle is 110 degrees. Door stoppers will automatically snap into their places when reaching a maximum opening angle. Door stoppers are installed in such a way that they should not impede any work on medium voltage and low voltage switchgears. The doors are fitted up with a 3 point-lock. The locks allow a profiled half-cylinder lock pad to be installed and are equipped with rain-protection escutcheon. When delivered, the lock will not include lock pads. As a standard solution the doors are made of 1.5 mm AlZn coated steel-sheet, and painted with a two component PU based painting. The metal parts are tested according to ISO 6988 standard. Roof Roof is designed as a separate constructional component which can be removed by lifting it off the supporting structure on the site when replacement is needed. Roof fixation is easy-to-access and detachable after opening the MV and LV doors. Option: Compact substation can be delivered with tile covered pitched roof. (see drawing no.: ABB ORION-630A- 05, ABB ORION-1000M-03). Corrosion protection Under normal circumstances the corrosion protection of various steel parts will be compliant for the entire substation lifetime. Ageing (corrosion) tests were carried out according to ISO 6988 standard. During the test, sulphur dioxide (SO2) in a concentration of 0.67% was applied under average humidity conditions. The unit under test was placed - with a cyclic alternation - in a sulphur dioxide bearing ambience at a temperature 40 C for a period of 8 hours, and in normal room atmosphere for a period of 16 hours. Upon the completion of 5 cycles, it could be observed by visual checkup that the surface was free of corrosion. Joints such as bolts and nuts are stainless. Surface finishing The external coating of substation is a scratch coat finishing directly applied onto the concrete. The surface layer is weatherproof, environment-friendly, UV resistant, and resistant to fungi. The interior of housing is not painted. Standard colouring of substation: ŮŮ external walls: RAL 9010 ŮŮ roof, doors and ventilation units: RAL 7032 pebble grey or anodized aluminium color Option: The compact substations, in addition to the above standard version, are also available with the following external surface finishing: ŮŮ rendered surface ŮŮ ornamental brick (see drawing no: ABB ORION-630A- 06, ABB ORION 1000M-04) Oil collection pit For Orion 400A and Orion 630A type compact substations: It is intended to trap, in case of a transformer failure, the insulating fluid flowing out of the transformer posing a danger to ambient groundwater. The basin with a capacity of 800 litres is gapless, fully confined, oil- and watertight. For Orion 1000M type compact substations: It is intended to trap, in case of a transformer failure, the insulating fluid flowing out of the transformer 6 ABB Catalogue 2009

7 technical description as it is dangerous to ambient groundwater. The basin with a capacity of 1000 litres is gapless, fully confined, oil- and watertight which is ensured without a supplementary coating. Cable connecting compartment Medium voltage and low voltage cables freely run to the connector zone of compact substation. The base part is fitted with cable entry openings whose upper, not sharp edge is located at a distance of 200 mm to the substation bottom. On request, the medium voltage cable inlets can be sealed against water with Hauff HRD type or Hauff HSI type of sealings. The separation walls of the basement is built up to the level of switchgear units so separation walls are used to separate the transformer room, medium voltage and low voltage cable compartments. The separation walls are arranged in such a way that the permissible bending radius specific to medium voltage cables and low voltage cables can be ensured. For the entry of cables to be connected temporarily (such as construction, standby power source / aggregate set), 2 pcs of openings (shuttable from inside) with a diameter of 100 mm are vailable, and they are formed in the wall of the substation, at the side of low voltage panel. Accessories room and low voltage door according to the local standards. As a basic solution, no internal lighting is installed inside the substation. Internal lighting can be installed upon request. External dimensions of substation: For compact substations type Orion 400A and Orion 630A: Outer dimension of housing without roof projection (drawing no. ABB ORION 630A-01): ŮŮ width: 1500 mm, ŮŮ height: 2500 mm, ŮŮ length: 3000 mm. Roof projection size reckoned from substation side wall: 100 mm The substation should be sunk under the ground level by 620 mm and this level is indicated on the building body Weight of the substation without equipment: 6000 kg. Weight of the substation with MV and LV equiment, without transformer: 7500 kg. * Orion 400A, 630A Compact Secondary Substation Weight of the substation with MV and LV equiment, with transformer: kg. For compact substation type Orion 1000M: Outer dimension of housing without roof projection (drawing no. xxxxx) ŮŮ widtht: 2400 mm, ŮŮ height: 2730 mm, ŮŮ length: 3100 mm. Roof projection size reckoned from substation side wall: mm The substation should be sunk under the ground level by 700 mm, that level is indicated on the building body Weight of the substation without equipment: kg. Weight of the substation with MV and LV equiment, without transformer: kg. Weight of the substation with MV and LV equiment, with transformer: kg. Accessories of the delivered substation include: ŮŮ Operating handle for medium voltage switchgear ŮŮ Documentations to the substation (Routine test reports, Installation and Operational Manuals, Electrical drawings) ŮŮ A prohibition signs saying /DO NOT TURN ON/ and /EARTHED AND SHORT CIRCUITED/, furnished with a magnetic foil on the rear side, for every medium voltage cable connection cubicle. ŮŮ Warning signs on the door of transformer room, medium voltage * Orion 1000M Compact Secondary Substation ABB Catalogue

8 általános leírás Asea Brown Boweri 3. Electrical equipment

9 electrical equipment Medium voltage switchgear SafeRing is an SF6 insulated ring main unit for the secondary distribution network. SafeRing is suitable for most switching applications in 12/24(25) kv distribution networks. It is extendible and combined with the SafePlus concept, which is ABB s flexible, modular compact switchgear, they represent a complete solution for 12/24(25) kv secondary distribution networks. SafeRing and SafePlus have identical user interfaces. SafeRing is a completely sealed system with a stainless steel tank containing all living parts and switching functions. A sealed steel tank with constant atmospheric conditions ensures a high level of reliability as well as personnel safety and a virtually maintenance-free system. The SafeRing concept offers a choice of either a switch fuse combination or circuit breaker with relay for protection of the transformer. As the first ring main unit, SafeRing can be supplied complete with an integral remote control and monitoring unit. The switchgears are equipped with manometer for monitoring the SF6 gas pressure inside the tank. The switchgear makes it possible to connect the substation on the 12 or 24 (25) kv network. The cable connection cubicle can be direct connection (De cubicle), or load break switch cubicle (C cubicle). The transformer cubicle can be fuse switch disconnector cubicle (F cubicle) or vacuum circuit breaker cubicle (V cubicle). As a standard the cubicles are manually operated, but upon request, can be equipped with motor operation. The cable connection cubicles are equipped with manually operated earthing switches intended for a direct earthing of cable connections. A mechanical interlocking will ensure that the cable cover cannot be removed unless the earthing switch is on. The unit has an operating handle having a length which allows comfortable operation of the unit without posing a risk of injury. Replacing fuse links in the fuse switch disconnector cubicle (F) can be done easily and without additional tools. The fuse base can be earthet both on busbar and cable side. The front cover of the fuse links are interlocked to the respective cubicle s earthing switch. The vacuum circuit breaker cubicle (V) contains vacuum breaking chambers. In line with the circuit breaker there is a 3 position isolator. There is a mechanical interlocking between the circuit breaker and the isolator. Behind the front cover of the circuit breaker a self powered protection relay can be found. The circuit breaker equipped with a low-energy tripping coil which is supplied by the ring type cable current transformers. The CTs are installed in the transformer cubicle s cable compartment. The basic protection is a 2-step time-overcurrent and earth fault protection. The switchgear is equipped with capacitive voltage indicators which make it possible tor run visual voltage detection and phase balance checks. It is possible to install short circuit and earth fault indicators (Alpha E, EKA3, etc) in the cable connection cubicles. 2-cubicle switchgears: KT: ABB SafeRing DeF 24, KL: ABB SafeRing DeV cubicle switchgears: KKT: ABB SafeRing CCF-24, KKL: ABB SafeRing CCV-24 4-cubicle switchgears: KKKT: ABB SafeRing CCCF-24 KKTT: ABB SafeRing CCFF-24 KKKL: ABB SafeRing CCCV-24 KKLL: ABB SafeRing CCVV-24 As a standard solution, the SafeRing switchgears are delivered with arcproof and interlocked cable cover. The cable connection cubicles of the switchgear can be equipped with RDA12 or RDA24 type surge arresters, using a RICS cable termination. Beyond the above described SafeRing switchgear, it is possible to install ABB SafePlus or other manufacturer s switchgear inside the medium voltage room of the substations. The switchgear unit complies with specifications of standard ABB SafeRing CCF-24 ABB Catalogue

10 electrical equipment IEC High voltage switchgear units Part 200: Metal enclosed AC switchgear unit rated for a nominal voltage of over 1 kv and up to 52 kv, including arc withstand capacity according to Approaches A and B, for all criteria (1 to 6). The built-in isolator switches comply with the specifications set out in standard IEC Medium voltage switchgears Part 1: Switchgear units rated for a nominal voltage of over 1 kv and up to 52 kv. The built-in fused isolator switch combination complies with the specifications set out in standard IEC High voltage switchgear units Part 105: AC fused isolator switch combinations. The built-in earthing switches and isolator switches comply with specifications set out in standard IEC High voltage switchgear units Part 102: High voltage AC isolators and earthing switches.. Nominal values for the SafeRing switchgear installed in the substation: 1. Nominal voltage 12/24(25) kv 2. Power frequency withstand voltage 28/50 kv 3. Impulse withstand voltage 95/125 kv 4. Rated frequency 50/60 Hz 5. Rated current busbars 630 A 6. Rated current (cable switch) 630 A 7. Rated current (T-off) 200 A Breaking capacities: 8. active load 630 A 9. closed loop (cable switch) off load cable charging (cable switch) off load transformer (T-off fuse) earth fault (cable swich) 200/150 A 13. earth fault cable charging (cable switch) 115/87 A 14. short circuit breaking current (T-off circuit breaker) 21/ Rated making capacity 52.5/ Rated making capacity (downstream fuse module) 12,5 17. Rated short time current 3 sec. 21/16 ka 18. Rated short time current 1 sec. (downstream fuse module) 5 ka Service conditions for indoor equipment according IEC Ambient temperature 19. Maximum value 40 C 20. Maximum value of 24 hours mean 35 C 21. Minimum value -25 C 22. Altitude for erection above sea level 1500 m 23. Relative humidity max 95 % 10 ABB Catalogue 2009

11 electrical equipment Rated values of load break switch installed in cable connection cubicle (C cubicle) 1. Rated current: 630 A 2. Rated breaking capacity active load: 630 A 3. Rated breaking capacity closed loop 630 A 4. Rated breaking capacity off load cable charging: 135 A 5. Rated breaking capacity earth fault: 200/150 A 6. Rated breaking capacity earth faul cable charging: 115/87 A 7. Rated making capacity: 52,5/40 ka 8. Type of mechanics: snap action 9. Electrical lifetime (at rated current): Mechanical lifetime: 1000 O/C Rated values of earthing switch installed in cable connection cubicle (C cubicle) 1. Rated current: 630 A 2. Rated making capacity 62,5 ka 3. Short time current: 21 ka 4. Time limit for short time current 3 s 5. Type of mechanics: snap action 6. Mechanical liftime: 1000 O/C Rated values of fuse load break switch installed in cable connection cubicle (F cubicle) 1. Rated current: 200 A 2. Rated making capacity limited by the fuse link 3. Rated breaking capacity off load transformer: 20 A 4. Type of mechanics: energy stored ( 2 springs) 5. Mechanical liftime: 1000 O/C The fuselink installed in the fuse holder of the switchgear can have the follwing dimension: ŮŮ In case of 24 kv (25kV): 442 mm ŮŮ In case of 12 kv: 292 mm, with a 150 mm fuse adapter Rated values of fuse circuit breaker cubicle (V cubicle): 1. Rated current: 200 A 2. Rated breaking capacity: 16 ka 3. Rated making capacity: 40 ka 4. Rated breaking capacity off load cable charging: 31,5 A 5. Switch on time of the circuit breaker: ms 6. Total switch off time of the circuit breaker: kb. 75 ms 7. Operating sequence: O-180s-C-O-180s-C-O 8. Mechanical liftime: 2000 C/O ABB Catalogue

12 electrical equipment Rated values of earthing switch 1. Rated current: 630 A 2. Rated making capacity 52,5/40 ka 3. Short time current 21/16 ka 4. Time limit for short time current: 3 s 5. Type of mechanics: snap action Medium voltage metering cubicle Type ABB M1060 Transformer room: Orion 400A type of substation: In the medium voltage room there is a possibility to install a medium voltage metering cubicle with 3 pcs of TPU 4(6) type current transformers and 3 pcs of TJC 4(6) type voltage transformers. The metering cubicle is situated right next to the medium voltage switchgear on the side of the transformer cubicle (F or V cubicle). The interconnection between the switchgear and metering cubicle is done by 3x1x35 mm2 N2XS type of medium voltage cable connection. The metering cubicle and the transformer are also connected with 3x1x35 mm2 N2XS type of medium voltage cables (please see drawing: ABB M ). In the transformer room one piece of maximum 400 kva oil insulated transformer can be placed. As a standard solution, the transformer is not included in the scope of delivery. The maximum dimensions of the transformer that can be installed in the transformer room are as follows: (length x width x height) 1550mm x 890mm x 1750 mm. The transformer is cooled by means of natural ventilation. Orion 630A type of substation In the transformer room one piece of maximum 630 kva oil insulated transformer can be placed. As a standard solution, the transformer is not included in the scope of delivery. The maximum dimensions of the transformer that can be installed in the transformer room are as follows: (length x width x height):1550mm x 890mm x 1750 mm. The transformer is cooled by means of natural ventilation ABB SafeRing DeV Switchgear with M1060 medium voltage measuring cubicle In case of Orion 400A and Orion 630A for controlling the no-load tap changer switch of transformer and monitoring the transformer compartment, a clearance of minimum 350 mm is provided between the medium voltage switchgear and the low voltage panel. A steel sheet with walk-resistant non-skid surface is installed onto the base. 12 ABB Catalogue 2009

13 electrical equipment Option: For a unit configuration in which the distance between medium voltage and low voltage units is less than 350 mm, a control opening is formed on the left hand side wall in order to allow the checkup of transformer compartment. This control opening has the following dimensions: width: 500 mm, height: 800 mm). Orion 1000M type of substation In the transformer room one piece of maximum 1000 kva oil insulated or cast resin insulated transformer can be placed. As a standard solution, the transformer is not included in the scope of delivery. The maximum dimensions of the transformer that can be installed in the transformer room are as follws: (L x W x H):1800mm x 1500mm x 2200 mm. The transformer is cooled by means of natural ventilation. For controlling the no-load tap changer switch of transformer and monitoring the transformer compartment, a control opening is formed on the right side wall. This control opening has the following dimensions: width: 500 mm, height: 800 mm). Medium voltage interconnections SafeRing type of medium voltage switchgear is installed inside the substation: The transformer and the switchgear are connected together with 3x1x35 mm2 N2XSY (or NA2XSY 95 mm2) 12/20 kv cable. The cable contains the cable termination at both end of the cable. At the transformer side a normal indoor cable termination is installed, while at the switchgear side insulated elbow connection is installed. Insulation test and upon request partial discharge test are performed on the cables. The related test certificates are part of the final documentation of the substation. SafeRing type of switchgear and M1060 type of metering cubicle are installed inside the substation: The SafeRing s transformer cubicle and the M1060 metering cubicle are connected together with 3x1x35 mm2 N2XSY (or NA2XSY 95 mm2) 12/20 kv cable. There is also a 3x1x35 mm2 (or NA2XSY 95 mm2) cable connection between the M1060 metering cubicle and the transformer. The cables contain normal indoor cable termination at the side of the transformer, incoming and outgoing outlets of the M1060 metering cubicle. The cable contains insulated elbow connection at the side of the switchgear. Insulation test and upon request, partial discharge test are performed on the cables. The test certificates are part of the final documetation of the substation. As a standard, the cable is earthed only on the side of the medium voltage switchgear. Each cable is marked with a uniqe and irremovable identification tag. To prove the adequacy of the cables, the test report contains the tags id and measured values for each cable. The cable terminations can be interchanged in the cable compartment to ensure the possibility of modifying the phase sequence according to the network condition. The medium voltage cables are not led through the low voltage room and do not cross low voltage cables. The medium voltage cables are connected to the transformer on a short circuit proof way and via the shortest route possible. ABB TNOSCTW 630 KVA type of oil insulated transformer ABB Catalogue

14 electrical equipment Low voltage distribution panel Orion 400A type of compact substation Parameters of low voltage panel: Perameters: 1. Rated voltage 420 V 2. Rated insulation level 690 V 3. Rated impulse voltage withstand capacity 6 kv 4. Rated frequency 50 Hz 5. Rated current of busbar 630 A 6. Thermal current of busbar 25 ka 7. Time limit for thermal current 1 s 8. Dynamic current of busbar 52,5 ka 9. Rated current of low voltage outgoings (fuse switch) 630 A,400 A, 250 A, 160 A 10. Incoming switch can be removable busbar load break switch circuit breaker 11. Nominal conditional short-circuit current of outgoings 80 ka General description The low voltage panel installed in the substation has a typified construction. Its type is: LV A - K/ABB type of LV panel LV-630-A-K/ABB. Nominal current of the unit is 630 A. The low voltage panel is a metal base plate containing insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substation. The low voltage panel is type tested and complies with specifications prescribed in standard IEC : Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin plated copper and have the cross section of 40x10 mm. The distance between the phase bars are 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low voltage fuse switches. The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for connecting the outgoing cables PEN conductor. The PEN bar is equipped with V-clamps for easy connection of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for connecting the temporary cables PEN conductor and other outer earthings. The busbar is well-marked with the symbols of L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock protection of the low voltage panel is TN-C (four conductor system). The IP protection class of panel is IP2X. The low voltage panel,as a basic, can be equipped with 8 pcs of NH 2 size (400 A) fuse switches. According to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows for the accommodation of 1 pc of A4 sized network map scheme inside it. On request the distribution panel can be delivered with low voltage surge arrasters which 14 ABB Catalogue 2009

15 electrical equipment are installed on the main busbars in such a way that the operator can clearly see them even during operation. The low voltage panel as a basic solution contains the following: ŮŮ Removable busbars in the incoming. Removing this busbar section will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable busbar. Each of the removable busbars has a 13mm hole so an aggregate can be connected here using cable lugs. The removable busbar section area can only be accessed after removing the tranparent covering plate. The covering plate can be lead sealed. ŮŮ A-meter with 1 pcs of current transformer on L2 phase ŮŮ 1 piece of 16A socket with pro tection circuit ŮŮ Transformer thermal protection circuit ŮŮ Auxiliary circuit for short circuit indicator (EKA3) (optional) ŮŮ V-meter (optional) ŮŮ 3 pcs of 4 mm sized sockets for phase identification (option) ŮŮ Internal lighting (optional) ŮŮ Capacitor bank supplied via NH00 size fuse switch (option) Incoming of low voltage panel The upper part of low voltage busbars (L1, L2, L3, PEN) are shaped to ensure that 2 pcs of insulated copper cables can be connected per phase. As a basic solution the incoming is a removable busbar, but can be changed to 630A load break switch or circuit breaker which protects the low voltage panel against short circuits and overcurrents. After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate connection ear is always covered by a front plate (IP2x). Low voltage outgoings The basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches. The panel can be enlarged with an extension module. The extension module can receive 4 more NH2 size fuse switches. The connection elements of the fuse switches enable us to connect 4x240 mm2 sm/50 mm2 low voltage cables. Orion 630A type of compact substation Parameters of low voltage panel: Perameters: 1. Rated voltage 420 V 2. Rated insulation level 690 V 3. Rated impulse voltage withstand capacity 6 kv 4. Rated frequency 50 Hz 5. Rated current of busbar 1250 A 6. Thermal current of busbar 25 ka 7. Time limit for thermal current 1 s 8. Dynamic current of busbar 52,5 ka 9. Rated current of low voltage outgoings (fuse switch) 630 A,400 A, 250 A, 160 A 10. Incoming switch can be removable busbar load break switch circuit breaker 11. Nominal conditional short-circuit current of outgoings 80 ka General description The low voltage panel installed in the substation has a typified construction. Its type is: LV-1250-A-K/ ABB. Nominal current of the unit is 1250 A. The low voltage panel is a metal base plate containing the insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substation. The low voltage panel is type tested and complies with specifications prescribed in standard IEC : Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin ABB Catalogue

16 electrical equipment LV A - K/ABB type of LV panel plated copper and have the cross section of 60x10 mm. The distance between the phase bars is 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low voltage fuse switches. The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for connecting the outgoing cables PEN conductor. The PEN bar is equipped with V-clamps to ensure easy connection of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for connecting the temporary cables PEN conductor and other outer earthings. The busbar is well-marked with the symbols of L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock protection of the low voltage panel is TN-C (four conductor system). The IP protection class of the panel is IP2X. The low voltage panel,as a basic, can be equipped with 8 pcs of NH 2 size (400 A) fuse switch. According to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows for the accommodation of 1 pc of A4 sized network map scheme inside it. On request the distribution panel can be delivered with low voltage surge arrasters which are installed on the main busbars in such a way that the operator can clearly see them even during the operation. The low voltage panel as a basic solution contains the following: ŮŮ Removable busbars in the incoming. Removing this busbar section will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable busbar. Each removable busbar has a 13mm hole so an aggregate can be connected here using cable lug. The removable busbar section area can only be accessed after removing the tranparent covering plate. The covering plate can be lead sealed. ŮŮ A-meter with 1 pcs of current transformer on L2 phase ŮŮ 1 piece of 16A socket with protection circuit ŮŮ Transformer thermal protection circuit ŮŮ Auxiliary circuit for short circuit indicator (EKA3) (optional) ŮŮ V-meter (optional) ŮŮ 3 pcs of 4 mm sized sockets for phase identification (option) ŮŮ Internal lighting (optional) ŮŮ Capacitor bank supplied via NH00 size fuse switch (option) Incoming of low voltage panel The upper parts of low voltage busbars (L1, L2, L3, PEN) are shaped to ensure that 3 pcs of insulated copper cables can be connected per phase. As a basic solution, the incoming is a removable busbar, but can be changed to 1250A load break switch or circuit breaker which protects the low voltage panel against short circuits and overcurrents. After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate connection ear is always covered by a front plate (IP2x). Low voltage outgoings The basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches. The panel can be enlarged with an extension module. The extension module can receive 4 more NH2 size fuse switches. The connection elements of the fuse switches allow to connect 4x240 mm2 sm/50 mm2 low voltage cables. 16 ABB Catalogue 2009

17 electrical equipment Orion 1000M type of compact substation Parameters of low voltage panel: Perameters: 1. Rated voltage 420 V 2. Rated insulation level 690 V 3. Rated impulse voltage withstand capacity 6 kv 4. Rated frequency 50 Hz 5. Rated current of busbar 1600 A 6. Thermal current of busbar 25 ka 7. Time limit for thermal current 1 s 8. Dynamic current of busbar 52,5 ka 9. Rated current of low voltage outgoings (fuse switch) 630 A,400 A, 250 A, 160 A 10. Incoming switch can be removable busbar load break switch circuit breaker 11. Nominal conditional short-circuit current of outgoings 80 ka ABB Orion 1000M type of Compact Secondary Substation ABB Catalogue

18 electrical equipment General description The low voltage panel installed in the substation has a typified construction. Its type is: LV-1600-A-K/ ABB. Nominal current of the unit is 1600 A. The low voltage panel is a metal base plate containign the insulators, low voltage busbars (L1, L2, L3 PEN), and low voltage equipment. The low voltage panel is installed in the low voltage room and the panel is fixed to the inserts of the internal walls of the substation. The low voltage panel is type tested and complies with specifications prescribed in standard IEC : Low voltage switchgear and controlgears, Part 1: Typified and partially typified units. The low voltage busbars are made from tin plated copper and have the cross section of 80x10 mm. The distance between the phase bars is 185 mm. The busbars contain M12 pressed-in screw nuts at the scale interval of 100 mm for installing the low voltage fuse switches. The PEN bar is provided with steel M12 pressed-in screw nut at the scale interval of 100 mm for connecting the outgoing cables PEN conductor. The PEN bar is equipped with V-clamps to ensure the easy connection of PEN conductors. The PEN bar is also provided with 4 pcs of M12x35 threaded bolts with the incident spring washers and screws for connecting the temporary cables PEN conductor and other outer earthings. The busbar is well-marked with the symbols L1, L2, L3 and PEN to ensure easy identifacition of the phases. The electric shock protection of the low voltage panel is TN-C (four conductor system). The IP protection class of panel is IP2X. The low voltage panel,as a basic, can be equipped with 12 pcs of NH 2 size (400 A) fuse switches. According to customer request the panel can also be equipped with NH 00 (160A), NH1 (250A), NH3 (630A) size of fuse switches. Each fuse switch of the low voltage panel is marked with a durable and clearly visible label. The low voltage panel allows the accommodation of 1 pc of A4 sized network map scheme inside it. On request, the distribution panel can be delivered with low voltage surge arrasters which are installed on the main busbars in such a way that the operator can clearly see them even during the operation. The low voltage panel as a basic solution contains the following: ŮŮ Removable busbars in the incoming. Removing this busbar section will separate the transformer from the outgoings. It is possible to install 3 pcs of low voltage current transformers on the separable busbar. Each removable busbar has a 13mm hole so an aggregate can be connected here using cable lug. The removable busbar section area can only be accessed after removing the tranparent covering plate. The covering plate can be lead sealed. ŮŮ A-meter with 1 pcs of current transformer on L2 phase ŮŮ 1 piece of 16A socket with protection circuit ŮŮ Transformer thermal protection circuit ŮŮ Auxiliary circuit for short circuit indicator (EKA3) (optional) ŮŮ V-meter (optional) ŮŮ 3 pcs of 4 mm sized sockets for phase identification (option) ŮŮ Internal lighting (optional) ŮŮ Capacitor bank supplied via NH00 size fuse switch (option) Incoming of low voltage panel The upper parts of low voltage busbars (L1, L2, L3, PEN) are shaped in such a way that 5 pcs of insulated copper cables can be connected per phase. As a basic solution the incoming is a removable busbar, but can be changed to 1600A load break switch or circuit breaker which protects the low voltage panel against short circuits and overcurrents. After the removable busbar or the incoming switching device the busbar is provided with aggregate connection ear with a 13 mm hole in it. The aggregate connection ear is always covered by a front plate (IP2x). Low voltage outgoings The basic low voltage panel can be equipped with 8 pcs of NH2 size (400A) fuse switches. The panel can be enlarged with an extension module. The extension module can receive 4 or 6 more NH2 size fuse switches. The connection elements of the fuse switches make it possible to connect 4x240 mm2 sm/50 mm2 low voltage cables. ABB Tmax type of CB ABB XLBM2 18 ABB Catalogue 2009

19 electrical equipment Description of optional items: Capacitor bank unit The substation can be equipped with a capacitor unit connected through a fuse switch. The power factor capacitors applied comply with test specifications prescribed in standard IEC Power capacitors, low voltage power factor capacitor banks. The nominal current of fuse link to be inserted is indicated on the fused isolator switch. Nominal power of capacitors: Orion 400A Orion 630A Orion 1000M 10 kvar 15 kvar 20 kvar Public lighting modul On the left-hand side of the low voltage panel a 350 mm wide space is available for the public lighting modul (PLM). In the incoming of the PLM there is a NH00 size fuse switch and a contactor. The contolling circuit of the contactor contains a 3 position switch (off, on, remote control) so the PLM can be swithed on locally or remote controlled. On the PLM free space and wiring are available for installing a power meter. The PLM contains 12 pcs of 32A MCB outgoings. The outgoing terminals of the PLM allow connection of cables with a maximum cross section of 70 mm2. Large consumer module Public lighting modul (PLM) This module is adjusted to the design of the standard low voltage panel. Left from the power infeed, an NH4 size fuse switch (with 1250 A knives) can be installed. This fuse switch allows the connection of 4 pcs of 240 mm2 cable conductors per phase. When supplied, 4 pcs of bolted plastic press plate type cable fasteners, in size adjusted to cable size are supplied with the large consumer module. Equipment installed into the low voltage distribution panel Parameters of fuse switches installed into the low voltage panel. The built-in fuse switches comply with test specifications as set out in standard IEC Low voltage switchgear and controlgear Part 3: Switches, isolators, isolator switches and fused switchgear combinations. The application category of units: AC-22 B type (non-frequent activation, permanent operation). The fuse switch allows to connect unprepared conductors to a terminal by means of a fastening piece (Vclamps). The fuse switches can be 1-pole or 3-pole operated according to customer request. Maximum cross section for connecting cable is 4x240 mm2 sm/50 mm2. Fuse bases do not include low voltage fuse links. Overcurrent protection MCBs: The installed overcurrent protection MCBs comply with test specifications as set out in standard IEC Low voltage switchgear and controlgear Part 2: Circuit breakers. Type of device applied: Nominal current: 2, 4, 6, 16 A Features of overcurrent protection MCBs: Features Unit Quantity 1. Nominal operating voltage (Ue) V Nominal insulation voltage (Ui) V Nominal frequency Hz Nominal short-circuit breaking capacity (Icn) in auxiliary circuits: ka 25* Upon request fuses can be installed instead of MCBs in the auxiliary circuits. ABB Catalogue

20 electrical equipment Low voltage interconnection between transformer and low voltage panel Orion 400A: The low voltage cable connection between the low voltage panel and the transformer can be: Using NSGAFÖU type of 185mm2 single phase cable: Phases: 2 pcs/phase PEN:2 pcs/phase Using H07V-K type of 240 mm2 single phase cable: Phases: 2 pcs/phase PEN:2 pcs/phase The NSGAFÖU type of cable is insulated for 1.8/3 kv, the H07V-K type of cable is insulated for 450/750V. The cable ends are assembled with cable lugs. Orion 630A : The low voltage cable connection between the low voltage panel and the transformer can be: Using NSGAFÖU type of 185mm2 single phase cable: Phases: 3 pcs/phase PEN:3 pcs/phase Using H07V-K type of 240 mm2 single phase cable: Phases: 3 pcs/phase PEN:3 pcs/phase The NSGAFÖU type of cable is insulated for 1.8/3 kv, the H07V-K type of cable is insulated for 450/750V. The cable ends are assembled with cable lugs. Orion 1000M The low voltage cable connection between the low voltage panel and the transformer can be: Using NSGAFÖU type of 185mm2 single phase cable: Phases: 4 pcs/phase PEN:4 pcs/phase Using H07V-K type of 240 mm2 single phase cable: Phases: 4 pcs/phase PEN:4 pcs/phase The NSGAFÖU type of cable is insulated for 1.8/3 kv, the H07V-K type of cable is insulated for 450/750V. The cable ends are assembled with cable lugs. Cabeling of transformer s thermal protection and gas protection : The wiring is done by 3x1.5mm2 MT cable. The cable can be found in the transformer room. This cable has to be connected to the transformer s protection unit according to the drawing attached to the substation s final documentation. The other side of the MT cable is connected by the factory to the tripping coil of the medium voltage switchgears s transformer cubicle. On request the thermal protection can also be wired to the main circuit breaker of the low voltage panel. 20 ABB Catalogue 2009

21 the maximal technical containt of the substation 4. The maximal technical containt of the substations The maximal technical containt of the substations can be found in the below chart. Orion 400A and Orion 630A type of substations Medium voltage switchgear Safering DeF, CCF, DeV, CCV X X Safering CCCF, CCFF, CCCV, CCVV X X Low voltage panel Incoming Removable busbar X X X X Fuse switch X X X X Circuit breaker X X X X Public lighting modul x x Outgoings Maximal number of NH2 size fuse switch (size of NH1, NH3 are identical to NH2, 2 pcs of NH00 is identical to pcs of NH 2) Capacitor bank unit X X X X Medium voltage switchgear Safering DeF, CCF, DeV, CCV Safering CCCF, CCFF, CCCV, CCVV Orion 1000M type of substation M1060 metering cubicle X - Low voltage panel Incoming Removable busbar X X Fuse switch X X Circuit breaker X X Public lighting modul X - Outgoings Maximal number of NH2 size fuse switch (size of NH1, NH3 are identical to NH2, 2 pcs of NH00 is identical to pcs of NH 2) Capacitor bank unit X X X X Remarks: ŮŮ Instead of 1 pcs of NH1, NH2, NH3 fuse switch 2 pcs of NH 00 size fuse switch can be installed. Adapter is needed when NH00 size fuse switch is installed instead of NH1, NH2 or NH3 fuse switch. ŮŮ The Orion 1000M type of substation can contain a maximum of 4-cubicle SafeRing 36 type of switchgear. ABB Catalogue

22 markings, tests, standards, guidelines and legislation 5. Markings The safety signs inside and outside the substation are made according to the local requirements. As a standard the substation is provided with the following signs: ŮŮ Five safety rules of neutralization procedure ŮŮ What to do in case of electric shock ŮŮ Warning sign on the medium voltage room and transformer room (lightning symbol and Caution! High Voltage! Danger to Life!, warning sign on the low voltage door (DANGER! 400V!) ŮŮ Data plate of the substation (manufacturer, year and place of production, production number) 6. Tests Type tests The following type tests have been performed on the substation in accordance with IEC standard. The tests were accomplished in an accredited and independent laboratory. ŮŮ Corrosion tests ŮŮ IP tests ŮŮ Mechanical tests ŮŮ Noise emission tests ŮŮ Heat-run test ŮŮ Dielectric test ŮŮ Short circuit tests ŮŮ Operational tests ŮŮ EMC test (measurement of magnetic field) ŮŮ Arc-fault tests Routine tests, acceptance tests The routine tests specified for substation and installed equipment will be performed on the site of manufacturer, after the substation has been manufactured. The protocol of routine test comprise the following tests according to standard IEC ŮŮ Dielectric test on high voltage interconnection ŮŮ Test on auxiliary and control circuits ŮŮ Functional tests (check of substation and installed components) ŮŮ Verification of correct wiring The routine test report is part of the substation final documentation and will be delivered together with the substation. 7. Standards, guidelines and legislation All components, assemblies, materials and parts are in compliance with relevant standards being effective and with generally recognized technical rules. The substation does not contain any material containing PCB or asbestos, or halogenized hydrocarbons or any other hazardous materials to be mandatorily marked. The compact substation has been manufactured in accordance with standards and laws as listed hereinafter. 22 ABB Catalogue 2009

23 standards, guidelines and ligislation IEC IEC standard voltages IEC ISO/IEC GUIDE 74 IEC IEC IEC IEC IEC IEC IEC IEC IEC Protection against electric shock Graphical symbols Technical guidelines for the consideration of consumers needs Power cables with extruded insulation and their accessories for rated voltages from 1 kv (Um = 1,2 kv) up to 30 kv (Um = 36 kv) - Part 1: Cables for rated voltages of 1 kv (Um = 1,2 kv) and 3 kv (Um = 3,6 kv) Power cables with extruded insulation and their accessories for rated voltages from 1 kv (Um = 1,2 kv) up to 30 kv (Um = 36 kv) - Part 2: Cables for rated voltages from 6 kv (Um = 7,2 kv) up to 30 kv (Um = 36 kv) Power cables with extruded insulation and their accessories for rated voltages from 1 kv (Um = 1,2 kv) up to 30 kv (Um = 36 kv) - Part 4: Test requirements on accessories for cables with rated voltages from 6 kv (Um = 7,2 kv) up to 30 kv (Um = 36 kv) Basic and safety principles for man-machine interface, marking and identification Identification of conductors by colours or alphanumerics Electrical installations of buildings - Fundamental principles Electrical installations of buildings - Protection for safety - Protection against electric shock Electric cables - Calculation of the current rating - Current rating equations (100% load factor) and calculation of losses - General Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests Instrument transformers, current transformers IEC Standardized current values according to IEC IEC IEC IEC IEC IEC IEC Metal oxide surge diverters without spark gap, for AC systems High voltage switchgears: switchgears rated for a nominal voltage of over 1 kv and less than 52 kv Low voltage fuses. General specifications Low voltage fuses. Additional requirements relevant to fuses used by authorized personnel High voltage fuses. Current limiting fuses Metal enclosed AC switchgear units rated for a nominal voltage of over 1 kv and up to 52 kv ABB Catalogue

24 standards, guidelines and legislation IEC IEC IEC IEC IEC IEC IEC IEC Low voltage switchgears and controlgears, Part 1: Typified and partially typified units Man-machine link, basic principles of safety for designation and identification. Identification of electric product terminals and dedicated conductor ends including alphanumerical rules thereof Man-machine link, basic principles of safety for designation and identification. Principles of operation Protection degrees provided by enclosure of electric products Electric drawing symbols. Switchgears, controlgears and protective devices Testing indoor type line-post insulators made of organic matter for systems rated for a nominal voltage of over 1 kv and less than 300 kv Common specifications of standards for high voltage switchgear units Overcurrent protection cutouts for household and similar units IEC Low voltage switchgears and controlgears. General specifications IEC IEC IEC IEC IEC IEC IEC IEC ISO 6988 Low voltage switchgears and controlgears. Part 2: Circuit breakers Low voltage switchgears and controlgears. Part 3: Switches, isolators, isolator switches and fused switch combinations Connector components. Electric copper conductors. Safety requirements for fastening units with and without bolt. Work under live voltage. Portable earthing, or earthing and short circuiting devices Marking nominal data of power supply on electric equipment. Safety requirements Power capacitors. Low voltage power factor capacitor banks High voltage switchgear units, Part 105: AC fuse-switchgear combinations High voltage switchgear units, Part 200: Metal enclosed AC switchgear units rated for a nominal voltage of over 1 kv and up to 52 kv Metallic and other inorganic coats. Testing with sulphur dioxide during condensation 24 ABB Catalogue 2009

25 standards, guidelines and ligislation IEC 50 International Electrotechnical Dictionary IEC 129 IEC 273 IEC 1238 IEC ISO/IEC IEC BImSchV AC isolators and earthing switches Specifications of indoor and outdoor line post insulators of systems rated for a nominal voltage of over 1 kv Pressed and mechanical joining pieces for copper or aluminium conductors of power cables Power cables with extruded insulation, for a nominal voltage ranging from 1 kv (Um=1.2 kv) to 30 kv (Um=36 kv) and their fittings. Evaluation of compliance. Declaration of supplier on compliance. High -voltage switchgear and controlgear - Part 202: Prefabricated HV/LV substations On health limits concerning inhabitants, specific to electric, magnetic and electromagnetic fields in the frequency range from 0 Hz to 300 GHz ABB Catalogue

26 Attachment 8. Attachments ABB SafeRing type of SF6 insulated compact medium voltage switchgear 2 way units: ŮŮ Height: 1336 mm ŮŮ Width: 696 mm ŮŮ Depth: 765 mm 3 way units ŮŮ Height: 1336 mm ŮŮ Width: 1021 mm ŮŮ Depth: 765 mm 4 way units ŮŮ Height: 1336 mm ŮŮ Width: 1346 mm ŮŮ Depth: 765 mm 26 ABB Catalogue 2009

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42 installation 9. Installation Manual for ABB Orion 400A and Orion 630A compact secondary substations For the erection and installation of ABB Orion 400 and Orion 630 compact substations, no complicated and timeconsuming operations are needed. For the installation, neither a concrete foundation nor any other special trade civil work is required. Erecting the substation consists of lifting it by means of a crane into a preliminary made base pit. Erection As a first step of erection, excavate a base pit in size corresponding to the compact substation (Figs. 6 and 7). Pit dimensions: - length: substation length mm = 4000 mm - width: substation width mm = 2500 mm - depth: 920 mm (substation excavation depth: 620 mm) Prepare a 300 mm thick bed consisting of a mixture of gravel and sand with a diameter of 7 to 25 mm, at the bottom of excavated base pit. Ram, then level the gravel bed. When the obtained bed is perfectly leveled, foundation work is considered to be completed. As a next step, crane the substation into the base pit. To lift the substation, use special RD36 type lifting eyes (4 pcs) insertable into threaded holes in the side wall of transformer substation. They are supplied by ABB for lifting when delivering the compact substation (Fig. 1). To lift the substation into place use a dedicated crane with a safety working load corresponding to the weight of the compact substation, and two lifting rod. The lifting rods are provided by ABB for lifting when delivering the compact substation. The weight of Orion 400A and Orion 630A substation is 7500 kg (without transformer). After the substation has been erected into the base pit, a clearance of at least 200 mm must be provided between the lowest point of substation door frame and the ground level, in order to allow for appropriate operability of units, proper ventilation of the substation, and to avoid ingress of water into the substation. Fig ABB Catalogue 2009

43 installation Installation To lift the transformer to its place, carry out the following operations after the compact transformer substation has been erected. To lift the transformer into its place by means of a crane, remove the substation roof. The roof is secured to the concrete body by means of 2 pcs of M16 bolts which are found at two diagonally opposite corners of the roof inside the substation. At the other two diagonally opposite corners of the substation, two additional steel centre pins are found which are intended to help you position and fix the roof (Fig. 2). As a first step, remove bolts fixing the roof (2 pcs of M16 bolts) shown in Fig. 2. To lift off the roof, screw lifting eyes supplied with the substation into bores located on the two longitudinal sides of the roof (Fig. 3). Then, the roof can be lifted off, and the transformer can be lifted into the substation. To ensure appropriate ventilation for the transformer, mount wheels of transformer beneath the transformer, and install a vibration absorber underlay under each wheel. Fig.2 ABB Catalogue

44 installation In the compact substation, medium voltage and low voltage cables with cross section and number corresponding to the transformer rated power are provided, as follows. For 400 kva: Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kv type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side). Low voltage cables: 4x2x1x185 mm2 NSGAFöU 1,8/3kV (or H07K-V 4x2x1x240 mm2). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue). For 630 kva: Fig.3 Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kv type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side). Low voltage cable: 4x3x1x185 mm2 NSGAFöU 1,8/3kV (or 4x3x1x185 mm2 H07K-V). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue). After the transformer has been lifted to its place by means of a crane on the site, connect medium voltage and low voltage cables provided and connect earthing cables to earthing points of the transformer. If the transformer has a thermal protection, also connect the 3x1.5 mm2 MT cable to the transformer thermal protection unit s N.O. trip contacts according to a circuit diagram shown in a manual supplied with the substation. After the transformer has been connected, replace the roof. Finally remove lifting eyes used for lifting the roof (Fig. 3). Insert the 2 pcs of M16 bolts fixing the roof back into the holes. It is recommended to store dismantled lifting eyes in the cable space of low voltage compartment. During the installation of the compact substation, install an appropriate shock protection system around the substation according to relevant standards in such a way that earthing resistance should be less than 2 ohms. Inside the transformer substation, the electric units, the metal supporting structures, and doors and windows are at Fig.4 44 ABB Catalogue 2009

45 installation factory earthed in the shortest route. Inside the substation, a shock protection junction has been installed (Fig. 4) in the low voltage compartment. It is that point to which the earthing conductors of installed equipments, the metal parts found inside the substation and the PEN bar of the low voltage panel are connected, using a 50 and 70 mm2, respectively, green/yellow wire (with a cable lugs at both cable ends). If the transformer is installed into the station on the site, then its earthing points must also be connected to the above mentioned junction, using the available earthing conductor. The external earthing network and potential control frame shall be entered into the substation through a low voltage cable entry found in the sidewall of substation. Connect the external earthing network (earthing frame) to the PEN bar. To connect the earthing conductor (or flat steel piece) a hole with a diameter of 13 mm is provided on the PEN bar. The external potential control frame must be connected to the bonding (potential equalization) bar. To connect the frame, a hole with a diameter of 11 mm is provided on the bonding bar. The installed external earthing system must be connected using safe and durable electric and mechanical joints. In the transformer substation, medium voltage and low voltage cables with cross section and number corresponding to the rated power of the transformer are provided, as follows. Fig.5 If Hauff HRD cable glands are to be installed, observe the following mounting sequence: Before entering medium voltage cables into the substation, pass the cables through the cable gland. Then, connect each cable to the medium voltage switchgear, and insert the gland into a rupture in the concrete. After adjusting the cables, use the M6 bolts to fix the sealing. By fastening the bolts, the rubber sealing will fill the space between cables, and the space between the gland and the concrete hole, thereby ensuring watertight condition of cable entries. In case of using Hauff HSI system: The core element of the HSI cable gland is embedded into the concrete foundation. After removing the covering plate of the core element, the adequate HSI cable gland has to be installed into its place. The HSI set contains heat shrinking tubes, what need to be put on the cable gland before entering the cable to the substation. When the cables are connected, the sealing can be realized by heating the shrinking tubes on the cable gland. Please study carefully the manual of the cable gland! Upon completion of installation, perform backfill of surplus earth and compact it. It is recommended to lay walkresistant paving tiles in a width of 80 cm around the substation. Documents concerning the operation and maintenance of installed equipment are provided in the Substation Manual which will be delivered with the substation and should be normally kept in a document holder on the internal side of the substation. ABB Catalogue

46 installation Fig.6 Fig.7 46 ABB Catalogue 2009

47 10. Installation Manual for ABB Orion 1000M type of compact secondary substation installation For the erection and installation of ABB Orion 1000M compact substations, no complicated and time-consuming operations are needed. For the installation, neither a concrete foundation nor any other special trade civil work is required. Erecting the substation consists of lifting it by means of a crane into a preliminary made base pit. Erection As a first step of erection, excavate a base pit in size corresponding to the compact substation (Figs. 6 and 7). Pit dimensions: - length: substation length mm = 4100 mm - width: substation width mm = 3400 mm - depth: 920 mm (substation excavation depth: 620 mm) Prepare a 300 mm thick bed consisting of a mixture of gravel and sand with a diameter of 7 to 25 mm, at the bottom of excavated base pit. Ram, then level the gravel bed. When the obtained bed is perfectly leveled, foundation work is considered to be completed. As a next step, crane the substation into the base pit. To lift the substation, use special RD36 type lifting eyes (4 pcs) insertable into threaded holes in the side wall of transformer substation. They are supplied by ABB for lifting when delivering the compact substation (Fig. 1). To lift the substation into place use a dedicated crane with a safety working load corresponding to the weight of the compact substation, and two lifting rod. The lifting rods are provided by ABB for lifting when delivering the compact substation. The weight of Orion 1000M substation is kg (without transformer). After the substation has been erected into the base pit, a clearance of at least 200 mm must be provided between the lowest point of substation door frame and the ground level, in order to allow for appropriate operability of units, proper ventilation of the substation, and to avoid ingress of water into the substation. Fig.1 ABB Catalogue

48 installation Installation To lift the transformer to its place, carry out the following operations after the compact transformer substation has been erected. To lift the transformer into its place by means of a crane, remove the substation roof. The roof is secured to the concrete body by means of 2 pcs of M16 bolts which are found at two diagonally opposite corners of the roof inside the substation. At the other two diagonally opposite corners of the substation, two additional steel centre pins are found which are intended to help you position and fix the roof (Fig. 2). As a first step, remove bolts fixing the roof (2 pcs of M16 bolts) shown in Fig. 2. To lift off the roof, screw lifting eyes supplied with the substation into bores located on the two longitudinal sides of the roof (Fig. 3). Then, the roof can be lifted off, and the transformer can be lifted into the substation. To ensure appropriate ventilation for the transformer, mount wheels of transformer beneath the transformer, and install a vibration absorber underlay under each wheel. Fig.2 48 ABB Catalogue 2009

49 installation In the compact substation, medium voltage and low voltage cables with cross section and number corresponding to the rated power of the transformer are provided, as follows. For 630 kva: Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kv type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side). Low voltage cables: 4x3x1x185 mm2 NSGAFöU 1,8/3kV (or H07K-V 4x3x1x240 mm2). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue). Fig.3 For 1000 kva: Medium voltage cable: N2XSY 3x1x35 mm2 12/20 kv type cable, mounted with a cable termination at both ends (with a Size 12 cable lugs on the transformer side). Low voltage cable: 4x4x1x185 mm2 NSGAFöU 1,8/3kV (or 4x4x1x185 mm2 H07K-V). Mounted with M12 size cable lugs at one end, with cable lugs and shrinking tube supplied for the other cable end (colour marking of conductors: L1: green, L2: yellow, L3: red, N: blue). After the transformer has been lifted to its place by means of a crane on the site, connect medium voltage and low voltage cables provided and connect earthing cables to earthing points of the transformer. If the transformer has a thermal protection, also connect the 3x1.5 mm2 MT cable to the transformer thermal protection unit s N.O. trip contacts according to a circuit diagram shown in a manual supplied with the substation. After the transformer has been connected, replace the roof. Finally remove lifting eyes used for lifting the roof (Fig. 3). Fig.4 ABB Catalogue

50 installation Insert the 2 pcs of M16 bolts fixing the roof back into the holes. It is recommended to store dismantled lifting eyes in the cable space of low voltage compartment. During the installation of the compact substation, install an appropriate shock protection system around the substation according to relevant standards in such a way that earthing resistance should be less than 2 ohms. Fig.5 Inside the transformer substation, the electric units, the metal supporting structures, and doors and windows are at-factory earthed in the shortest route. Inside the substation, a shock protection junction has been installed (Fig. 4) in the low voltage compartment. It is that point to which the earthing conductors of installed equipments, the metal parts found inside the substation and the PEN bar of the low voltage panel are connected, using a 50 and 70 mm2, respectively, green/yellow wire (with a cable lugs at both cable ends). If the transformer is installed into the station on the site, then its earthing points must also be connected to the above mentioned junction, using the available earthing conductor. The external earthing network and potential control frame shall be entered into the substation through a low voltage cable entry found in the sidewall of substation. Connect the external earthing network (earthing frame) to the PEN bar. To connect the earthing conductor (or flat steel piece) a hole with a diameter of 13 mm is provided on the PEN bar. The external potential control frame must be connected to the bonding (potential equalization) bar. To connect the frame, a hole with a diameter of 11 mm is provided on the bonding bar. The installed external earthing system must be connected using safe and durable electric and mechanical joints. Medium voltage cable entries are not at-factory sealed. Upon request, ABB can provide cable glands (Hauff HRD) to seal them (Fig. 5). The substation can be supplied with Hauff HSI type of cable glands as well. If Hauff HRD cable glands are to be installed, observe the following mounting sequence: Before entering medium voltage cables into the substation, pass the cables through the cable gland. Then, connect each cable to the medium voltage switchgear, and insert the gland into a rupture in the concrete. After adjusting the cables, use the M6 bolts to fix the sealing. By fastening the bolts, the rubber sealing will fill the space between cables, and the space between the gland and the concrete hole, thereby ensuring watertight condition of cable entries. In case of using Hauff HSI system: The core element of the HSI cable gland is embedded into the concrete foundation. After removing the covering plate of the core element, the adequate HSI cable gland has to be installed into its place. The HSI set contains heat shrinking tubes, what need to be put on the cable gland before entering the cable to the substation. When the cables are connected, the sealing can be realized by heating the shrinking tubes on the cable gland. Please study carefully the manual of the cable gland! Upon completion of installation, perform backfill of surplus earth and compact it. It is recommended to lay walkresistant paving tiles in a width of 80 cm around the substation. Documents concerning the operation and maintenance of installed equipment are provided in the Substation Manual which will be delivered with the substation and should be normally kept in a document holder in the internal side of the substation. 50 ABB Catalogue 2009

51 installation Fig.6 Fig.7 ABB Catalogue

52 operating and maintenance manual 11. ABB Orion 400A, ABB Orion 630A and ABB Orion 1000M type Concrete Compact Secondary Substations Operating and Maintenance Manual General rules Entry into the substation is forbidden, and is impossible due to the fact that the room is very tight. So, in regard to type, these substations are outside operated. Do not touch or enter any part - not intended for operation - of the substation until the substation has been made dead (neutralized). As a standard solution the doors are fitted-up with a 3 point lock. The locks allow a profiled half-cylinder lock pad to be installed. Each door is equipped with a door stopper which automatically latches when the door reaches its end position. The latch of the door stopper must be released before closing the door. Upon completion of control and maintenance of the substation, close the doors of the compact substation, and before leaving check whether the doors are properly closed and locked. Operation of ORION 400A and ORION 630A Operating the transformer substation is possible from outside, after opening a double-leafed door on a longitudinal side of the transformer substation. The right hand side door has a lock in order to prevent unauthorized from entering. The low voltage panel is found - when looking at the longitudinal side of transformer substation equipped with a door - behind the right hand side door. After opening and propping up the door you can control the low voltage compartment from outside. The door of medium voltage compartment is found to the left and cannot be opened until the low voltage compartment door has been opened, by moving the push locks installed at the top and bottom parts of the door. The SF6 insulated medium voltage switchgear unit (RMU) is found behind the left hand door. As standard, a three-cubicle SafeRing CCF type switchgear unit will be installed in the medium voltage compartment of the compact substation. In that case, the transformer compartment will have no door. In such case, an access to the tap changing switch of transformer will be accessible, after opening both door leaves, through a free space between the medium voltage switchgear unit and the low voltage panel. Should a 4-cubicle SafeRing CCCF type switchgear unit be installed in the medium voltage compartment, an additional transformer door will be built on the shorter wall on the side of the transformer substation, found toward the low voltage panel. In that case, the tap changing switch of transformer will be accessible from there. Operation of ORION 1000M In case of ORION 1000M the medium voltage switchgear and low voltage panel can be found in two different compartments. Both compartments can be accessed after opening the double-leafed door. There are concrete separation walls among the transformer room, the medium voltage compartment and the low voltage compartment. As a basic solution the transformer room has a separate door. The tap changing switch of the transformer can be accessed from here. As a standard the substation is equipped with a 3-way SafeRing CCF, but a 4 or 5-cubicle RMU can also be installed. Operation and maintenance of medium voltage unit The operation and maintenance of the switchgear must be performed according to Instructions for Installation and Operation titled SafeRing / SafePlus SF6-insulated Ring Main Unit and Compact Switchgear Installation and operating instructions (No: 1VDD GB NOPO- WSR 5976 GB) Turning the medium voltage unit on and off Load break switches installed into line cubicles type C of the switchgear unit have a snap action mechanism. They are operated with a double-arm operating handle belonging to the switchgear unit accessories. Direction of rotation is clearly indicated on the front panel of medium voltage switchgear. An unintentional switching operation is excluded because even the insertion of operating handle 52 ABB Katalógus 2009

53 operating and maintenance manual is prevented by means of a mechanical cover of the driving stud in order to avoid a forbidden operation. Switching state is indicated by position indicators linked with the load break switch mechanism, fit to the switching scheme on the front panel. Closing covers are found in front of the switching coulisses, allowing any of the three switching positions - ON, OFF, Earthed - to be padlocked. An isolator switch installed into transformer cubicle type F has spring energy storage drive which is at default manually operated but can also be tripped by an N.O. release which operates in the case where the thermal protection unit of transformer has tripped, or by means of a mechanism fitted to a striker mechanically indicating fuse blowout. As a result, even a single pole blowout of fuse link will cause 3-pole disconnection. Voltage checkup Capacitive voltage dividers are installed into the bushings realizing a medium voltage cable connection of the switchgear. As a standard, the ON state of power is indicated by a VPIS type integrated voltage indicators (LED) on the front panel of the given cubicle of the switchgear. Identification of the phases is achieved by labels on the front of the voltage indicator. Removing the cable compartment cover The cable compartment cover of line and transformer cubicles of switchgear and the fuse space cover of transformer cubicle are interlocked with the earthed position of an insulator switch installed in the given cubicle. Covers may not be removed unless the isolator switch is earthed, so always make sure - before opening the cover - that the isolator switch is earthed. Fuse insertion and replacement To handle fuse space - after turning off the cubicle s isolator switch - turn earthing switch on. A red display at the bottom part of front panel, beneath the fuse link symbol indicates fuse blowout. Fused switch cubicles (F- modules) are delivered without fuse links. Perform fuse replacement always in all of the three phases, and ensure that the striker should be in the required position. The required position is indicated on the internal side of the fuse canister s covering plate. Cable connection SafeRing / SafePlus switchgear units are equipped with outer cone bushings which comply with specifications for cable connectors set out in DIN 47636T1 and T2/EDF HN standards. Possible exchange of phases has absolutely no problem for single-phase cables. For 3 phase cables - due to the tight cable space - take special care when cutting them to size and inserting them in such a way that the cable should remain straight at the cable terminations. How to handle SF6 gas The switchgear unit is completely sealed which means that SF6 gas is inside a solid enclosure. Handling the SF6 gas requires no special instructions, specifications, rules. The unit is always supplied with a pressure indicating manometer. Before operating the unit, always check gas pressure on the manometer. If the pointer is in the green zone, pressure is okay. If the pointer is in the red zone, pressure is very low, and do not operate the unit. In that case, fill the unit with gas after switching-around neutralization. For an arcing fault, arc products (decomposition products of SF6, combustion products of insulant) will get first into the cable space, then through the arc cooling channel into the transformer space, then to open air and will disperse within a short period. SF6 gas is an inert gas with large molecules, existing in the atmosphere as well. Its decomposition products and the combustion products of insulant and the metal vapours are toxic when in high concentration. Proceed as follows to remove small amount of SF6 gas residual in the substation: ŮŮ After a trouble causing an arcing fault, do not approach the substation neutralized on the power feed side and do not stay near it until the fume having an unpleasant odour has dispersed. ŮŮ After opening the substation doors, parts found at a deep point such as transformer oil collection pit, cable spaces must be vacuum cleaned. Then, dust bag must be annihilated. ŮŮ Neutralize a possibly produced white powder using lime hydrate or sodium carbonate solution. ŮŮ Wash the cover using sodium bicarbonate solution. Operating the low voltage panel Only skilled and properly trained personnel may operate the low voltage panel. The Operator shall be responsible for ensuring and checking it. The operation of unit must be regulated in Instructions for Operation to be issued by the Operator. The operating personnel shall bring with them the safety facilities required for the operation of the unit. If required by the Customer, the earthing/short-circuiting device will form part of the transformer substation. During maintenance operation, specifications indicated in standards shown in the Instructions for Operation shall be governing, and relevant labour safety and accident prevention rules and precautions must be observed. Agents, washing fluids used for the work may be fire hazardous, accident hazardous and harmful to health, therefore, use them as intended only, with an enhanced caution. The low voltage panel requires no special fire protection measures. ABB Catalogue

54 operating and maintenance manual Operating the low voltage panel The low voltage outgoing feeders (fused switches) are suitable for conducting, making and breaking normal currents and small overload Maintenance Checking the technical condition Check the unit visually at least once a year, for the following: ŮŮ Is sufficient room provided for the work? ŮŮ Condition of low voltage distribution unit ŮŮ Number and intact state of switching devices ŮŮ Readouts shown by built-in instruments ŮŮ Condition of built-in fuse links. currents. Apply a vigorous movement to pull out fuse base cover when turning the unit off, and to push it back when turning on. When turning off one fused switch, push back the switch cover without fuse link. This state of fuse base Instructions for maintenance Use only materials of the same type as the original one for the maintenance of the unit because the properties, function and physical parameters of other types may be different. Maintenance work on the compact substation shall be performed by personnel belonging to the Operator, or by authorized personnel appointed by the Operator. Before maintenance operation, neutralize the substation by disconnecting will prevent live points from being touched upon, and the transparent covers will allow checking disconnected state. For high overload or fault currents the fuse will blow out according to its characteristics. the transformer cubicle of medium voltage switchgear. For any maintenance work on the low voltage line, the outgoing feeders must be earthed according to the following: ŮŮ Remove fuse links after opening switch covers. ŮŮ Connect clamp jaw contacts of the earthing unit to the PEN bar of the unit. ŮŮ Insert three connection elements - having a cover - of earthing device into L1, L2 and L3 phases of the unit. Materials required for maintenance operation Low voltage panel ŮŮ Remove dust from the low voltage room ŮŮ Clean ventilation surfaces ŮŮ Check connections, bars ŮŮ Check fixing pieces of installed devices and moving elements of the house (doors, door stopper, lock etc) ŮŮ Check fuse links ŮŮ Check existence of labels ŮŮ Check earthing cables and connections ŮŮ Check and clean insulators ŮŮ Check auxiliary and control circuits (internal lighting, socket, transformer thermal protection circuit, etc) ŮŮ If circuit breaker is installed, check the operation of the breaker and test the protection ŮŮ Check current joints once every 10 years 54 Medium voltage switchgear ŮŮ Check gas pressure in the medium voltage unit ŮŮ Clean MV switchgear and clean MV room ŮŮ Check operation of MV switchgear (open, closed, earthed positions) ŮŮ Check interlockings of the switchgear ŮŮ If circuit breaker panel is installed, check the operation and the protection of the circuit breaker Transformer and transformer room ŮŮ Clean transformer and transformer room ŮŮ Check the condition of MV and LV cables ŮŮ Check the condition of MV and LV connections ŮŮ Check thermal protection unit of transformer, and check the adherent circuit. ŮŮ Check the oil level of the transformer ŮŮ Check the earthing of the transformer ŮŮ Check insulation of the transformer (on the base of Operator decision) ŮŮ Collect oil sample from the transformer and test it (on the base of Operator decision) Materials required for maintenance operation ŮŮ Earthing short circuiting device ŮŮ Solvents, degreasing fluids, denatured alcohol, cloth, rag ŮŮ Vacuum cleaner ŮŮ Torque wrenches, screwdrivers, fork spans ŮŮ Double-hand operating handle ŮŮ Ampere and Volt meter (Multi Meter) ŮŮ Insulation tester ŮŮ Vial for oil sample ABB Catalogue 2009

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